Big Blue 400 Pro Issued Aug. 2017 Index No. ED/5.7 Diesel Engine-Driven Welder/AC Generator Quick Specs Heavy Industrial Applications Mechanical contractors Structural steelwork Fabrication Maintenance Repair Rental Construction Pipe welding Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) RMD * Pulsed MIG (GMAW-P)* DC TIG (GTAW) Air carbon arc (CAC-A) Rated: 3/16-inch (4.8 mm) carbons Capable: 1/4-inch (6.4 mm) carbons Output Range DC stick 20 400 A DC TIG 20 400 A FCAW/MIG 14 40 V Generator Output Rated at 104 F (40 C) 12,000 watts peak, 10,000 watts continuous *Available only on ArcReach models. The professional welder s choice designed with the professional in mind, the Big Blue 400 Pro is the best for ease of use, reliability and fuel economy. DURABLE BUILT TO LAST Kubota V1505 four-cylinder diesel. Mitsubishi S4L2 four-cylinder diesel. CATERPILLAR C1.5 three-cylinder diesel. Heavy-duty low-speed T4F and T4i industrial diesel engines are designed to operate over 10,000 hours before the first basic overhaul. Backed by worldwide support and service. Remote control of the power source without a cord. See pages 2 and 3. Built to last in harsh industrial environments SUPERIOR ARC PERFORMANCE New standard for productivity and weld quality WELDS AROUND THE WORLD International models available FLEXIBLE USA model shown is Easy to add capabilities Welder/generator is warranted by Miller for three years, parts and labor. Engine is warranted separately by engine manufacturer. Miller Electric Mfg. Co. An ITW Welding Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA Equipment Sales US and Canada Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX: 920-735-4125 MillerWelds.com
Big Blue 400 Pro Features and Controls Digital meters with SunVision technology enable welding parameters to be viewed with greater clarity than analog meters at virtually any angle. Meters can be seen clearly even in direct sunlight. Meters display Process settings for quick and easy setup Preset and actual amperage Simple-to-set controls require no elaborate procedure just select process and weld! Industrial USB port. Quickly upload the latest software and download machine log files to retrieve in-depth information such as diagnostics and machine statistics. Low OCV stick (VRD), when enabled, reduces the open-circuit voltage to 30 volts when the welding power source is not in use, increasing operator safety without compromising arc starts. Thermal overload protection prevents machine damage if the duty cycle is exceeded or airflow is blocked. Standard features include adjustable Hot Start, output contactor control, automatic idle and 120-volt block heater. Arc control is beneficial when welding with stick and solid wires for easier fine-tuning of tough-to-weld materials and out-of-position applications. Standard 14-pin receptacle with Auto-Remote Sense for simple connection of remote controls and wire feeders. POWERFUL GENERATOR 10,000 watts of pure generator power. Plug in an extra Miller inverter-based power source for a second welding arc! HD POWDER COAT HD powder coat with zinc-rich primer protects sheet metal from rust and corrosion. Quiet operation. Improves worksite communication. ArcReach Remote Control Technology Remote control of the power source without a control cord. An ArcReach system allows you to change weld settings from your ArcReach feeder or remote, saving a trip to the power supply. ArcReach technology uses the existing weld cable to communicate welding control information between the feeder or remote and the power source. This technology eliminates the need for control cords, and their associated problems and costs. ArcReach engine drive ArcReach feeder or remote 2
Big Blue 400 Pro ArcReach Additional Features ArcReach provides remote amperage and voltage control at the weld joint without needing a control cord. MORE WELDS IN LESS TIME Increased productivity More arc-on time and reduced exposure to workplace hazards for operators can be realized using ArcReach because less time is spent going back to the welding power supply to set process and arc amperage or voltage. Auto-Process Select. Depending on connected accessory, the system automatically changes to stick or MIG/FCAW (with ) if electrode positive polarity is detected or TIG or FCAW (no ) if electrode negative polarity is detected, when ArcReach communication is established between the accessory and the Big Blue 400 Pro reducing the need to access the power supply. Automatic return to panel settings. System automatically returns to Big Blue 400 Pro setting when ArcReach communication is terminated. For example, if the Big Blue is set to gouging at 350 amps and an ArcReach feeder is connected, the Big Blue will go to a MIG/FCAW process. If the feeder is disconnected, the Big Blue will go back to its previous setting (gouging at 350 amps). Less operator fatigue by not needing to move or reposition heavy secondary weld leads bundled with control cords on the jobsite. Control cables are not used. BETTER WELDS WITH LESS REWORK Improved weld quality Operator can precisely set arc amperage or voltage at the weld joint and monitor the actual arc voltage and current delivered to the weld using the digital meters on the accessory. This removes guesswork when it comes to adhering to weld procedures. Remote override of Big Blue 400 Pro. When an ArcReach accessory is connected to a Big Blue the accessory has full control and the Big Blue controls are disabled. While under ArcReach control, process and voltage/amperage adjustments are locked out, preventing accidental changes by personnel other than the welding operator. FEWER CABLES TO MAINTAIN Save time by no longer needing to troubleshoot welding system problems that result from damaged control cords. Eliminate costly control cord repairs because control cords are not used. Reduced maintenance FLEET COMPATIBILTY Improved flexibilty Cross platform compatible. The same ArcReach accessories that work on engine-driven equipment can also be used on select ArcReach-equipped XMT and Dimension power sources. Reverse compatible. ArcReach-equipped power sources work with non-arcreach accessories; however, the complete ArcReach benefit is only realized with the ArcReach system. Big Blue 400 Pro ArcReach System and Accessories Big Blue 400 Pro ArcReach system (Kubota 907732001 or Mitsubishi 907733001), ArcReach SuitCase 12 feeder with Bernard S-Gun (951730), ArcReach Stick/TIG Remote (301325), and ArcReach Smart Feeder with Bernard PipeWorx 300-15 MIG gun (951733). Note: ArcReach is only available on USA models. ArcReach SuitCase 8 and 12 feeders for MIG or flux-cored welding Remote voltage control Polarity indication Auto-Process Select ArcReach Smart Feeder for advanced wire processes RMD and pulsed MIG processes Remote voltage control Store and recall weld settings ArcReach Stick/TIG Remote for stick or TIG welding Remote amperage control Arc control for stick Polarity indication Auto-Process Select 3
Specifications (Subject to change without notice.) Weld Mode/ Process Weld Output Range Weld Output Rated at 100% Duty Cycle at 104 F (40 C) Max. Open- Circuit Voltage Generator Power Output Rated at 104 F (40 C)** Sound Levels at Rated Output, 23 ft. (7 m) Dimensions Net Weight (without fuel)*** CC/DC (TIG) CC/DC (Stick) CV/DC (FCAW/MIG) 20 400 A 20 400 A 14 40 V 300 A at 32 VDC 350 A at 27 VDC 400 A at 24 VDC 85 VDC 30 VDC* 12,000 watts peak, 10,000 watts continuous 1-phase, 84/42 A, 120/240 VAC, 60 Hz Kubota Idle: 66 db (91 Lwa) Weld: 71.6 db (96 Lwa) Mitsubishi Idle: 68.7 db (93 Lwa) Weld: 72.1 db (97 Lwa) CAT Idle: 65 db (90 Lwa) Weld: 71.2 db (96 Lwa) H: 32 in. (813 mm) W: 26.25 in. (667 mm) D: 56 in. (1,422 mm) Kubota 950 lb. (431 kg) Mitsubishi 993 lb. (450 kg) CAT 1,010 lb. (458 kg) *Sense voltage for stick and Lift-Arc TIG. **Will operate either 60 Hz or 50/60 Hz power tools, lights, etc. ***Additional 82 lb. (37 kg) when fuel tank is full. Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Meets NEMA and IEC output ratings. CAT and Kubota powered international models are approved. Engine Specifications (Engines warranted separately by the engine manufacturer.) Engine Brand Mitsubishi S4L2 USA Features EPA Tier 4 Final compliant, includes 120 V block heater HP 24.7 Type Four-cylinder, liquid-cooled, industrial diesel Engine Speeds Idle: 1,500 rpm Weld: 1,800 rpm Capacities Fuel: 11.5 gal. (43.5 L) Oil: 5.8 qt. (5.5 L) Coolant: 10 qt. (9.5 L) Automatic Engine Shutdown Low oil pressure, high coolant temperature, low fuel level Kubota V1505 EPA Tier 4 Final compliant, includes 120 V block heater 20.2 Four-cylinder, liquid-cooled, industrial diesel Idle: 1,500 rpm Weld: 1,800 rpm Fuel: 11.5 gal. (43.5 L) Oil: 6 qt. (5.7 L) Coolant: 6 qt. (5.7 L) Low oil pressure, high coolant temperature, low fuel level Int l CATERPILLAR C1.5 EPA Tier 4i compliant, includes 120 V block heater 21.7 Three-cylinder, liquid-cooled, industrial diesel Idle: 1,500 rpm Weld: 1,800 rpm Fuel: 11.5 gal. (43.5 L) Oil: 5.9 qt. (5.6 L) Coolant: 6 qt. (5.7 L) Low oil pressure, high coolant temperature, low fuel level Performance Data Liters/Hr. 5.68 4.73 3.79 2.84 1.89 0.95 0.00 Us Gal./Hr. Fuel Consumption Curve 1.50 1.25 1.00 0.75 0.50 Idle 0.25 0.00 0 50 100 150 200 250 300 350 400 DC Weld Amperes at 100% Duty Cycle Simultaneous Welding and Power Weld Amperes Total Aux. Power Available (Watts) 25 A 10,000 75 A 10,000 125 A 10,000 175 A 9,000 225 A 7,500 300 A 4,500 350 A 1,000 4
Function Guide 1. Self-calibrating digital weld meters with fault code indication display preset or actual weld parameters. 2. Pushbutton main control knob used for adjusting amperage/voltage, adjusting arc control, and accessing the service menu. 3. LED process indicator. Front panel process selections are illuminated with an LED that identifies the active process. This enables the selected weld process to be seen at a distance from the power source. 4. Lift-Arc TIG with Auto-Stop and Auto-Crater. 5. USB port allows software updates from a USB drive. A summary file of recoded data from the unit will be saved to a USB drive that is inserted. 1 2 3 4 5 6 7 8 9 10 11 12 13 6. Weatherproof Lexan nameplate is super durable and resists cracking and fading. 7. Adjustable arc control adjusts DIG when process control is in stick mode and adjusts inductance when process control is in FCAW or MIG mode. The amount of DIG determines how much amperage (heat) varies with stick arc length. Inductance determines the wetness of the weld puddle. 8. Maintenance interval reminder. Yellow and red indicator lights let an operator know when the machine is approaching and finally in need of routine maintenance. 9. Fuel indicator gauge. Low fuel shutdown shuts engine off prior to running out of fuel to prevent loss of fuel in the system, and make restarts easy. 10. Glow plugs assist in cold weather starting. 11. Engine control switch is used to start the engine and then select between auto idle and high speed lock. 12. Standard 14-pin receptacle for simple connection of remote controls and wire feeders. Includes Auto Remote Sense which automatically switches from panel to remote amperage/voltage (A/V) control with remote connected. Eliminates confusion of a panel/remote switch. 13. 50 A, 120/240 V receptacle and 20 A, 120 V GFCI receptacles with circuit breakers Note: For matching 240 V plug, order 119172. 14. Weld output terminals 15. International receptacle panel with 16 A, 240 V receptacle, 20 A 120 V GFCI receptacle and 32 A, 240 V receptacle with circuit breakers Note: For matching 240 V, 16 A plug, order 255416 and for matching 240 V, 32 A plug, order 255418. ARC START with Lift-Arc Touch or scratch Workpiece Shielding Arc ARC END with Auto-Stop While welding Arc Workpiece Shielding Lift at any angle Lift up until arc ends ARC END with Auto-Crater While welding Arc Workpiece Shielding USA Model International Model Receptacles Shielding For Auto-Stop, lift up to terminate arc Arc ends without flare To start Auto-Crater, press momentary contact switch Welding current ramps down Reduces or eliminates sticking Reduces or eliminates electrode/ work contamination Low open-circuit voltage Move back down to maintain coverage Maintain shielding coverage Eliminates need for a remote control Maintains shielding coverage Eliminates tungsten and workpiece contamination Eliminates unwanted arc strikes outside the weld area 14 15 Maintains shielding coverage Eliminates tungsten and workpiece contamination Auto-Crater time allows for addition of filler Eliminates unwanted arc strikes outside the weld area 5
Genuine Miller Accessories Replacement 110 V Receptacle Panel 195356 Field For International models only. Replaces complete auxiliary power panel with one 110-volt, 16-amp and one 110-volt, 32-amp receptacle and Earth Leakage Circuit Breaker (ELCB) supplementary protector. Female Receptacle Full KVA Adapter Cord 300517 Field NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to common Millermatic and Spectrum 240 V plug. Full KVA Plug Kit 119172 Field 120/240 V, 50 A plug (NEMA 14-50P) to fit full KVA receptacle. International Plugs Field 255418 1-phase, 240 V, 32 A plug 255416 1-phase, 240 V, 16 A plug Engine Filter Kits 246987 Field. For CAT 253901 Field. For Kubota 252782 Field. For Mitsubishi Includes all filters required for proper engine maintenance. Oil filter, primary and secondary fuel filter, and primary air filter. Spark Arrestor (Muffler) Kit 300585 Field Prevents particles from leaving the muffler that could potentially start a fire. Mandatory when operating on California grasslands, brush, or forest-covered land, and in all national forests. For other areas, check your state and local laws. Meets U.S. Forest Service Standard 5100-1B. FA-1D Lockable Flame Arrestor Fuel Cap 043947 Field Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank. Protective Cover 195301 Field Blue water-resistant cover with Miller logo resists stains and mildew, and protects the finish of your welder. MIG (GMAW) or Flux-cored (FCAW) SuitCase X-TREME 8VS Wire Feeder 951582 SuitCase X-TREME 12VS Wire Feeder 951543 Lightweight, voltage-sensing wire feeders include secondary contactor, valve, drive roll kit and Bernard BTB Gun 300 A. See literature M/6.42. SuitCase 12RC Wire Feeder 951580 Lightweight and flexible enough to run wires up to.062-inch diameter. Includes remote voltage control, drive roll kit and Bernard BTB Gun 300 A. See literature M/6.5. ArcReach SuitCase 8 951726 With Bernard BTB Gun 300 A 951727 With Bernard S-Gun 951728 With Bernard Dura-Flux gun ArcReach SuitCase 12 951729 With Bernard BTB Gun 300 A 951730 With Bernard S-Gun 951731 With Bernard Dura-Flux gun Portable feeder designed to run off of arc voltage. When paired with an ArcReach power source, provides remote control of the power source without a control cord saving time and money. See literature M/6.55. ArcReach Smart Feeder 951733 For use with ArcReach models only (see page 2 for more information). Includes drive rolls and Bernard PipeWorx 300-15 MIG gun. For MIG, FCAW, and advanced RMD and pulse processes. See literature M/6.55. MIG (GMAW)/Flux-cored (FCAW) Guns See Bernard literature SP-BTB for BTB air-cooled MIG guns, and SP-DF for Dura-Flux self-shielded flux-cored guns. Spoolmatic 30A Spool Gun 130831 Air-cooled, 200-amp, one-pound spool gun for aluminum and stainless MIG. See literature M/1.73. Requires WC-24 Control (137549). XR Wire Feeders and Guns Push-pull system designed to handle difficultto-feed soft alloy wires such as aluminum. See literature M/1.7 through M/1.74. AC TIG (GTAW) Welding The Dynasty 210 power sources can be run off the engine drive s generator to provide two arcs with only one engine. Dynasty 210 Series For portable AC/DC TIG. See literature AD/4.81. Multiple Operator Welding The XMT 350 FieldPro and CST 280 power sources can be run off the engine drive s generator to provide two arcs with only one engine. XMT 350 Series See literature DC/18.93. CST 280 See literature DC/29.55. 6
Genuine Miller Accessories (Continued) Plasma Cutting Stick/TIG Remote Controls Spectrum 375 X-TREME and 625 X-TREME shown. Spectrum 375 X-TREME 907529 See literature PC/9.2. Spectrum 625 X-TREME 907579 See literature PC/9.6. Spectrum 875 907583 See literature PC/9.8. The Spectrum 375 X-TREME and 625 X-TREME come complete with protective X-CASE (not shown). ArcReach Stick/TIG Remote 301325 When paired with an ArcReach power source, provides remote control of the power source without a cord saving time and money. See literature AY/14.5. Wireless Remote Hand Control 300430 For remote current, voltage and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine. 300-foot (91.4 m) operating range. Wireless Antenna Kit 300749 Recommended for improved reception. RHC-14 Hand Control 242211020 Miniature hand control for remote current, voltage and contactor control. Dimensions: 4 x 4 x 3.25 in. (102 x 102 x 82 mm). Includes 20-foot (6 m) cord and 14-pin plug. RMS-14 On/Off Control 187208 Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5-foot (8 m) cord and 14-pin plug. RCC-14 Remote Contactor and Current Control 151086 East/west rotary-motion finger tip control attaches to TIG torch using two hook-and-loop fasteners. Includes 26.5-foot (8 m) cord and 14-pin plug. PRHC-14 Hand Control 195511 Complete current or voltage control brings 120 volts GFCI power to work area in a single cord. Housed in a durable, light aluminum case and includes 125-foot (38 m) cord with plugs. Extension Cables for 14-Pin Remote Controls or 24 VAC Wire Feeders 242208025 25 ft. (7.6 m) 242208050 50 ft. (15.2 m) 242208080 80 ft. (24.4 m) Trailers and Hitches (Note: Trailers are shipped unassembled.) Mounting Specifications F 4 holes HWY-Mid Frame Trailer 301438 1,424-pound (646 kg) capacity highway trailer with welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, fenders, lights, and dual hitch with 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye. Cable Tree 043826 Provides an area to conveniently wrap weld cables and extension cords. Dual Hitch 301441 Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly. 2-In-1 Document/ Fire Extinguisher Holder 301236 Stores documents and holds a 5-pound fire extinguisher. Note: Holder shown mounted on trailer. Fire extinguisher not included. A B Front Panel C D E A. 27.75 in. (705 mm) B. 26.25 in. (667 mm) C. 52.25 in. (1,327 mm) D. 2 in. (51 mm) E. 56 in. (1,422 mm) F..562 in. (14 mm) dia. Height: 32 in. (813 mm) Width: 26.25 in. (667 mm) Depth: 56 in. (1,422 mm) Trailer Specifications (Subject to change without notice.) Model HWY-Mid Frame Gross Axle Weight Rating 1,605 lb. (728 kg) Gross Vehicle Weight Rating 1,424 lb. (646 kg) Net Payload 1,424 lb. (646 kg) Height of Bed 19.5 in. (495 mm) Road Clearance 8 in. (203 mm) Track (Center to center of tires) 46 in. (1,168 mm) Standard Tires (Standard rating or P-size rating) ST175/80D-13 Load Range C Dimensions Length: 101 in. (2,565 mm) Width: 55 in. (1,397 mm)* Net Weight 181 lb. (82 kg) *Width at outside of fenders. 7
Ordering Information Equipment and Options Stock No. Description Qty. Price Big Blue 400 Pro 907732 Kubota. USA model 907733 Mitsubishi. USA model Big Blue 400 Pro ArcReach 907732001 Kubota. USA model 907733001 Mitsubishi. USA model Big Blue 400X Pro 907630 CAT (CE). International model 907631 Kubota (CE). International model Field Accessories Replacement 110 V Receptacle Panel 195356 Field. For International models only. 110 V, 16/32 A with ELCB Full KVA Adapter Cord 300517 Field Full KVA Plug Kit 119172 120/240 V. Field International Plugs Field. See page 5 Engine Filter Kit 246987 Field. For CAT, includes air, oil and fuel filters 253901 Field. For Kubota, includes air, oil and fuel filters 252782 Field. For Mitsubishi, includes air, oil and fuel filters Spark Arrestor (Muffler) Kit 300585 Field FA-1D Lockable Flame Arrestor Fuel Cap 043947 Field Protective Cover 195301 Field MIG/Flux-cored Welding SuitCase X-TREME 8VS 951582 With Bernard BTB Gun 300 A. See literature M/6.42 SuitCase X-TREME 12VS 951543 With Bernard BTB Gun 300 A. See literature M/6.42 SuitCase 12RC 951580 With Bernard BTB Gun 300 A. See literature M/6.5 ArcReach SuitCase 8 951726 With Bernard BTB Gun 300 A. See literature M/6.55 951727 With Bernard S-Gun 951728 With Bernard Dura-Flux gun ArcReach SuitCase 12 951729 With Bernard BTB Gun 300 A. See literature M/6.55 951730 With Bernard S-Gun 951731 With Bernard Dura-Flux gun ArcReach Smart Feeder 951733 MIG/FCAW/RMD /pulse feeder with Bernard PipeWorx 300-15 MIG gun. Tweco -style connectors. See literature M/6.55 MIG (GMAW) and Flux-cored (FCAW) Guns See Bernard literature SP-BTB and SP-DF Spoolmatic 30A Spool Gun 130831 Requires WC-24 Control. See literature M/1.73 WC-24 Control 137549 See literature M/1.73 XR Wire Feeder Control and Guns See literature M/1.7 through M/1.74 PipeWorx Memory Cards For use with ArcReach Smart Feeder only. See page 6 TIG Welding See page 6 Multiple Operator Welding See page 6 Plasma Cutting See page 7 Stick/TIG Remote Controls ArcReach Stick/TIG Remote 301325 For use with ArcReach models only Wireless Remote Hand Control 300430 Hand control with wireless 300 ft. (91.4 m) operating range Wireless Antenna Kit 300749 Recommended for improved reception RHC-14 Hand Control 242211020 Hand control with 20 ft. (6 m) cord RMS-14 On/Off Control 187208 Remote contactor control RCC-14 Remote Contactor and Current Control 151086 Fingertip control PRHC-14 Hand Control 195511 Hand control with 120 V GFCI receptacle, 125 ft. (38 m) Extension Cables See page 7 Trailers and Hitches HWY-Mid Frame 301438 Trailer with lights, fenders and dual hitch. For highway use Cable Tree 043826 Trailer-mounted cable holder Dual Hitch 301441 Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly 2-In-1 Document/Fire Extinguisher Holder 301236 Stores documents and holds a 5-pound fire extinguisher Date: Total Quoted Price: Distributed by: 2017 Miller Electric Mfg. Co.